Design of Compact Briquette Machineijream.org/papers/ICRTET0098.pdfof designing this compact unit is to integrate the processes involved in the briquetting and reduce the cycle time

International Journal for Research in Engineering Application & Management (IJREAM)

Special Issue – ICRTET-2018 ISSN : 2454-9150

514 | ICRTET0098 www.ijream.org © 2018, IJREAM All Rights Reserved.

Design of Compact Briquette Machine 1Aditya U. Tembhekar,

2Rohit D.Kabade,

3Parag K.Kasliwal,

4Mayuri R.Patil,

5Ankit S.Gujrathi

1Student,

2Student,

3Student,

4Student,

5Assistant professor

1Department of Mechanical Engineering, 1SNJB‟s K. B. Jain College of Engineering,Chandwad, India

Abstract: The paper presents the design of the compact briquette machine. This working model basically utilizes the dry coconut

waste as raw material which is the abundant source as biomass obtained from the religious places, farming sectors and local areas.

Molasses is the binding agent which is the by-product of sugar industry which is also the solid industrial waste. This paper

involves the design of motor, cutter, compaction mechanism and belt and pulley use as its primary components. The main purpose

of designing this compact unit is to integrate the processes involved in the briquetting and reduce the cycle time required for the

biomass production. The machine uses the shaft of 38mm diameter and the outer diameter of the screw is 55mm. This model

works on the 2Hp motor to drive the unit.

Index Terms–Briquettes, molasses.

I. INTRODUCTION

A briquette is a compressed block of coal dust or other combustible biomass material such as charcoal, sawdust, wood chips,

peat, or paper used for fuel and kindling to start a fire. The term comes from the French language and is related to brick.

Utilization of agricultural residues is often difficult due to their uneven and troublesome characteristics. The process of

compaction of residues into a product of higher density than the original raw material is known as densification or briquetting.

The briquette machine can be used in producing high quality wood shaft with low cost sawdust, corn cob and peanut shell, cotton

stalk, tree branch, etc. The final stick is with high density for the fuel. It is one of the newest energy recycle machine, which has

important use for the energy Industry. This machine is used for making the briquette from the sawdust, straw, hulls, coconut

waste etc. It is best fuel and the feedstuff of animal. The briquette can be used as the burning material for the boiler or fire place

for house warming. Briquettes can be produced with a density of 1200 kg/m3 from loose biomass of bulk density 100 to 200 kg

/m3 these can be burnt clean and therefore are eco-friendly. Due to their heterogeneous nature, biomass materials possess

inherently low bulk densities, and uneven and troublesome characteristics thus, it is difficult to efficiently handle large quantities

of most feed stocks. The process of compaction of residues into a product of higher density than the original raw material is

known as densification or briquetting.

Justina et al.[2] stated that the beginning of19th century, sawdust briquettes were made with tar or resins as the binders, but

could not gain importance at that time due to relatively higher costs compared to wood and charcoal. But re-emerged in the 1950s

when millions of tons of briquettes were produced and consumed . M.U. ajieh et al.[1] stated that here occur several materials

indicating machine designs or squeezes for wood briquetting especially in the developed countries of the world. Uniformly,

remarkable research from Authors across Asia shows that there is appreciable proof of wood briquetting as well as the use of

wood as fuel wood in the backwoods areas for cooking in an open fire or stove. In Sub-Saharan West Africa and the rest of

Africa, wood logging is predominantly used for direct combustion and building infrastructures. The subject of wood briquetting is

very common, however there exists a considerable number of literature on the use of solid waste and agricultural residues for

briquettes.Briquettes are largely combustible materials made from loose or low density wastes but compressed together into a

solid. The compression leads to a product of higher bulk density, „-uniform size and shape. Developing countries are facing huge

problem with waste management and agro residues such as coir pitch, dry leaves, rice husk, coffee husk etc., are contributing

majorly to this problem. We usually see these agro residues and saw mill residues are usually burnt on roadside or dump yards,

which again results in pollution. Majid Ali et al [4] suggesdted that there are two types of coconut fibres, brown fibre extracted from matured coconuts and

white fibres extracted from immature coconuts. Brown fibres are thick, strong and have high abrasion resistance. White fibres are

smoother and finer, but also weaker. Coconut fibres are commercial available in three forms, namely bristle (long fibres), mattress

(relatively short) and decorticated (mixed fibres). These different types of fibres have different uses depending upon the

requirement. In engineering, brown fibres are mostly used. According to official website of International Year for Natural Fibres

2009, approximately, 500000 tonnes of coconut fibres are produced annually worldwide, mainly in India and Sri Lanka. Its total

value is estimated at $100 million. India and Sri Lanka are also the main exporters, followed by Thailand, Vietnam, Philippines

and Indonesia. Around half of the coconut fibres produced is exported in the form of raw fibre. Muhammad SN et al [5]

investigated that most of the biomass materials are, however, not suitable for direct utilization, because they are fluffy, uneven in

size and shape and have very low density.These differences not only make difficult to handle, transport and store the biomass

material in raw form. There are numerous ways to resolve these problems, of which briquetting is the most commonly utilized

technologies. Kiran Kumar et al [3] studied the end use of briquettes is mainly for replacing coal in industry for heat applications

(steam generation, melting metals, space heating, brick kilns, tea curing, etc) and power generation through gasification of

biomass briquettes and for domestic uses.

6th International Conference on Recent Trends in Engineering & Technology (ICRTET - 2018)


II. METHODOLOGY

A briquette is a compressed block of coal dust or other combustible biomass material such as charcoal, sawdust, wood chips,

peat, or paper used for fuel and kindling to start a fire. The term comes from the French language and is related to brick. Utilization

of agricultural residues is often difficult due to their uneven and troublesome characteristics. The process of compaction of residues

into a product of higher density than the original raw material is known as densification or briquetting. Fig.1shows the isometric

view of the proposed machine.

The above fig.6 shows the isometric view of the proposed model having part details are as follows:

1. Hopper 9. Coupler

2. Pillow block bearing 10. Allen Bolt

3. Larger pulley 11. Mixer

4. Belt 12.Compaction barrel

5. Small pulley 13. Die

6. Motor 14. Frame

7. Speed reducer 15. Casing

8. Cutter shaft

Fig.1: Isometric View of proposed model

The main function of the frame and base is to give the support to the whole unit. In supports the cutter and casing unit, pedestal

bearings, extrusion and mixing unit, motor and die. For manufacturing of the frame the MS angles are used. The whole structure is

joined together by means of the welded joint. As shown in fig.2. the frame support structure. The design of frame is done by using

the Rankine‟s formula in which Wcr is the crippling load, „a‟ is the Rankine‟s constant for MS material and K is radius of

gyration.[6]

Rankine‟s Formula,

Fig.2: Design of support structure in CATIA




Prime mover is the basic part of this unit which is used to convert the electrical energy into useful motion. The drive units such

as the belts and pulleys are used to transmit the motion from prime mover to the driven units. The briquette machine utilizes the

electric motor as its prime mover to transmit the rotary motion to the cutter. The system requires electric motor to achieve the

rotary motion of the cutter. It converts the electrical energy into rotary motion. It not only give the power to cutter but also give

the power to the extrusion unit. In the above equation N is the rpm of cutter and T is the torque acted on it.

Power required to rotor,

[6]

As we are using the coconut biomass as our raw material which is having the maximum strength among all the other biomass.

The strength of the raw coconut husk fibre is 130N/mm.2. The maximum torque obtained at the rotor shaft is given by Tc = Fc x

R. where R is the radius of the rotor, Fc is the force acting on the rotor. The fig.3 shows the design of the cutters which are

mounted on the rotor.

Fig.3: Design of cutter in CATIA

The power required to overcome frictional losses can be computed assuming 10% losses due to frictional forces. Essentially, the

shaft is designed on the basis of strength, rigidity and stiffness. The shaft is the main component of the cutter section. The rotor is

also mounted on the rotating shaft. The rotor consists of the different small cutters are mounted on it. The above equation will give

the value of diameter of shaft in which the „d‟ indicates the diameter of shaft, indicates the permissible shear stress, „T‟

indicates the torque, „m‟ indicates the maximum bending moment.[6]

√

The main function of the pulley and belt drive is used to transmit the power and torque from motor shaft to the cutter rotor

which is mounted on the shaft. The pulleys are used. As the large sized pulley is use at the cutter shaft while the small size pulley

is mounted on the motor output shaft. The available data is input power, Pin= 2 Hp=1.5 kw, input speed, N1=1440 rpm,

approximate central distance, C=584 mm. As the system is motor driven and medium duty application (<10hrs/day duty) So,

service factor can be selected as Fa= 1.1.

Fig.4: Design of belt and pulley in CATIA

Fig.4 shows the design of belt and pulley in CATIA. As per the design power calculations and the speed of faster pulley we‟ve

to select “A-grade” v-belt by using graph relation. Speed ratio and pulley pair selection. i

where N indicates the speed.

Pitch length, L =

6th International Conference on Recent Trends in Engineering & Technology (ICRTET - 2018)


Exact central distance, C= A + √

Where, A=

[

] and B =

Length of arc of contact for smaller pulley, Ɵ = [

]

Belt speed, V =

Belt Rating, kWrating = [

]

Number of belts required, Z=

=

= 1.92 = 2

The speed reducer is the basically used to transmit the power from the input power of the cutter to the output screw which is

used for the extrusion. The reducer transmits the power without losses. It transmits the power to the screw shaft which is in

perpendicular direction with the cutter shaft. The speed which is required for the solid and liquid mixing of the molasses and the

husk waste is ranges from the 60 to 120 rpm. So, we have selected worm gearbox as per the specifications of worm gearbox,

/q / m where Zw is the number of teeth on worm, Zg is the number of teeth on gear, „q‟ is the dimeteral quotient and „m‟

is the module. Fig.5. shows the worm speed reducer. [6]

Fig.5: Speed reducer in CATIA

In a screw extruder, the rotating screw takes the material from the feed port, through the cone section of the mixer unit, and

compact it against a die which assists the build-up of a pressure gradient along the screw. During this process the biomass is

forced into intimate and substantially sliding contact with the barrel walls. This also causes frictional effects due to shearing and

working of biomass.

The combined effects of the friction caused at the barrel wall, the heat due to internal friction in the material and high rotational

speed of the screw cause an increase in temperature in the closed system which helps in heating the biomass. Then it is forced

through the extrusion die, where the briquette with the required shape is formed. At this stage just before entering the die, the

pressure exerted is maximum. If the die is tapered the biomass gets further compacted. Fig.6 shows the compaction screw made in

CATIA. The tangential force acting on screw is given by

The radial force is given by,

[

]




Fig.6: compaction screw made in CATIA

III. RESULTS AND DISCUSSION

Table. 01: Design Specification

Sr. Parameter Data

1 Electric Motor 2Hp

2 Belt Designation A56

3 Large pulley diameter 127 mm

4 Small pulley diameter 50 mm

5 Centre distance 560 mm

6 Blade dimensions 38 x 2 mm

7 Cutter shaft diameter 38 mm

8 Screw Diameter M56

9 Gear ratio 15

10 No. of belts required 2

11 Angle dimensions 35 x35x 2.5 mm

12 Kw rating 0.9825

13 Speed reducer designation 2/30/10/4 14 Force on screw 3189.03 N

CONCLUSION

This project produces the briquettes from the waste biomass sources such as coconut husks as well as the other biomass. As we

have already seen the design of this compact machine. It is more compact than the existing machines with better product output.

Apart from the existing machines this machine integrates the processes involved in it, so this will ultimately reduces the cycle time

required for the briquettes production.

REFERENCES

[1]. M. U. Ajieh, A. C Igboanugo and T. O. K. Audu, Design of grass briquette machine, Nijotech, July 2016, PP. 527 – 530,

ISSN: 2467-8821.

[2]. Arinola B. Ajayi, Justina I. OsumuneDept. of Mechanical Engineering, Faculty of Engineering, University of Lagos, Lagos.

Nigeria.ISSN 2222-1727 (Paper) ISSN 2222-2871 (Online)Vol.4, No.10, 2013.

[3]. Kishan B, Kiran Kumar, Santhosh T J, Amith D, Gangadhar, Design and fabrication of low cost briquetting machine and

estimation of calorific values of biomass briquettes, IJIRSET, 7 july 2016, ISSN(Online) : 2319-8753.

[4]. Majid Ali, second international conference on sustainable construction materials and technology, university of

politechnicadellemarche,Ancona, Italy, 30 june-2010, ISBN-975-1-4507-1490-7.

[5]. Muhammad SN, Muhammad AA, Abdul N, Anjum M (2016) Design and Fabrication of Biomass Extruder of 50Mm

Diameter Briquette Size. InnovEner Res 5: 128.

[6]. V.B. Bhandari, Design of machine element, edition-3, 2010, Tata Mcgraw Hill publication, ISBN: 978-0-07068179-8.

[7]. www.bp.com/en/global/corporate/energy-economics/statistical-review-of-world-energy/coal/coal

consumption

[8]. http://coconutboard.nic.in/stat.html

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Design of Compact Briquette Machineijream.org/papers/ICRTET0098.pdfof designing this compact unit is to integrate the processes involved in the briquetting and reduce the cycle time